Starting System & Charging System (H4SO): Other Subaru Outback BR

2.5 L MODEL

ITEM SPECIFICATION

3.6 L MODEL

ITEM SPECIFICATION

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1. 2.5 L model

Scheme 62

1. 3.6 L model

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CAUTION

1. Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
2. Remove contamination including dirt and corrosion before removal, installation or disassembly.
3. Keep the disassembled parts in order and protect them from dust and dirt.
4. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly and replacement.
5. Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
6. Be sure to tighten fasteners including bolts and nuts to the specified torque.
7. Place shop jacks or rigid racks at the specified points.
8. Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.

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1. Disconnect the ground cable from battery.
2. Remove the air intake boot assembly, (non-turbo model) Ref. to «REMOVAL»(ref-371894-S06764648272010091900000) , Air Intake Boot. Ref. to «REMOVAL»(ref-371896-S05520593882010091900000) , Air Intake Boot.
3. Remove the intercooler. (turbo model) Ref. to «REMOVAL»(ref-371895-S26814185912010091900000) , Intercooler.
4. Disconnect connector (B) and terminal (A) from starter.
5. Remove the starter from transmission. NOTE: For the MT model, a bolt is used in place (A).

DIODE

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1. Check for continuity between the diode lead and terminal E or B. If continuity is not as shown in the table, replace the rectifier. At analog type tester CONTINUITY CHART Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 Yes B No P1, P2, P3, P4, P5, P6 E No B Yes At digital type tester CONTINUITY CHART Tester lead Continuity -lead +lead E P1, P2, P3, P4, P5, P6 No B Yes P1, P2, P3, P4, P5, P6 E Yes B No

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1. Slip ring surface Inspect the slip rings for contamination or any roughness on the sliding surface. Repair the slip ring surface using a lathe or sand paper.
2. Slip ring outer diameter Measure the slip ring outer diameter. Replace the rotor assembly if the slip ring is worn. Slip ring outer diameter: Standard 22.7 mm (0.894 in) Service limit 22.1 mm (0.870 in)
3. Continuity test Using a circuit tester, check the resistance between slip rings. If the resistance is not within the standard, replace the rotor assembly. Specified resistance: Approximately 2.0 - 2.3 ohms
4. Insulation test Check the continuity between slip ring and rotor core or shaft. If there is continuity, replace the rotor assembly because the rotor coil is grounded.
5. Bearing (rear side) Check the bearing (rear side). If there is any noise, or the rotor does not rotate smoothly, replace the bearings.

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1. Continuity test Inspect the continuity between the stator coil terminals. If continuity is not as shown in the table, replace the stator coil.
2. Insulation test Inspect the continuity between the stator coil stator core and lead wire terminals. If there is continuity, replace the stator coil because the stator coil is grounded.

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1. Measure the length of each brush. Replace the brush if wear exceeds service limits. There is a service limit mark (A) on each brush. Brush length: Standard (1) 22.5 mm (0.886 in) Service limit (2) 5.0 mm (0.197 in)
2. Check that there is appropriate pressure on the brush spring. Using a spring pressure indicator, push the brush into the brush holder until its tip protrudes 2 mm (0.08 in). Then measure the pressure of brush spring. If the pressure is 1.7 N (173 gf, 6.11 ozf) or less, replace the brush spring. 4.1 - 5.3 N (418 - 540 gf, 14.75 - 19.06 ozf) pressure is required on the new spring.

BALL BEARING (FRONT SIDE)

Check the ball bearings. Replace the ball bearings if there is resistance in the rotation, or if there is any abnormal noise.

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1. After disconnecting the battery ground terminal, remove the terminal cover, then disconnect the positive terminal.
2. Remove the battery cable holder from the battery rod.
3. Remove flange nut from the battery rod and remove battery holder.
4. Remove the battery.

EXTERNAL PARTS

Check the battery case, top cover, vent plugs, and terminal posts for dirt or cracks. If necessary, clean with water and wipe with a dry cloth.

Apply a thin coat of grease on the terminal posts to prevent corrosion.

ELECTROLYTE LEVEL

Check the electrolyte level in each cell. If the level is below MIN level, bring the level to MAX level by pouring distilled water into the battery cell. Do not fill beyond MAX level.

Scheme 76

1. Measure specific gravity of electrolyte using a hydrometer and a thermometer. Specific gravity varies with temperature of electrolyte so that it must be corrected at 20°C (68°F) using the following calculation: S 20 = St + 0.0007 x (t - 20) S 20 : Specific gravity corrected at electrolyte temperature of 20°C (68°F) St: Measured specific gravity t: Measured temperature (°C) Judge whether or not battery must be charged, according to corrected specific gravity. Standard specific gravity: 1.220 - 1.290 [at 20°C (68°F)]
2. Measuring the specific gravity of the electrolyte in the battery will disclose the state of charge of the battery. The relation between specific gravity and state of charge is as shown in the figure.

MEASUREMENT

JUDGMENT OF BATTERY IN CHARGED CONDITION

1. Specific gravity of electrolyte should be held within the specific range from 1.250 to 1.290 for one hour or more.
2. Voltage per battery cell should be held at a specific value in a range from 2.5 to 2.8 V for one hour or more.

CHECK CONDITION OF CHARGE WITH HYDROMETER

HYDROMETER INDICATOR SPECIFICATION

NORMAL CHARGING

Charge the battery at the current value specified by manufacturer or at approximately 1/10 of battery's ampere-hour rating.

QUICK CHARGING

Quick charging is a method that the battery is charged in a short period of time with a relatively large current by using a quick charger.

Since a large current flow raises electrolyte temperature, the battery is subject to damage if the large current is used for prolonged time. For this reason, the quick charging must be carried out within a current range that will not increase the electrolyte temperature above 40°C (104°F).

Also the quick charging is a temporary mean to bring battery voltage up to some level, and battery should be charged slowly with low current as a rule.